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The cement industry must lead the sustainable journey

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Umashankar Choudhary, Unit Head, JK Cement throws light on the alternative fuels and raw materials that can be used in the production of cement which can lead to a significant reduction in energy and fuel consumption and also meet the organisation’s goals of achieving a lesser carbon footprint in the environment.

What are the raw materials and fuels currently used by your organisation in the cement manufacturing process?
In the process of cement manufacturing, the major constituent is clicker which we produce in our plants. Major raw materials for this clinker production are limestone which contributes to 97 to 98 per cent and the rest are additives. Mainly we use the DCP dust which is added around 2 per cent. This is also an alternative raw material because we are focusing on alternative raw material as well as alternative fuels for the clinker manufacturing.
In cement, we add additives like on gas, slag, and gypsum. Gypsum is of two types, namely, chemical and mineral. We use both chemical and mineral gypsum as per their availability and cost economy. As we speak about fuels, the major fuel is coal. However, now we want to maximise the use of alternative fuels, so we have started using RDF, MSW, hazardous industrial waste in the form of RDF which constitutes to about 70 to 80 per cent of the alternative fuel mix.

Please tell us more about the constitution of these alternative fuels and why they are chosen as alternative fuels.
Alternative fuels are chosen because they are available in abundance. Our plant is located in Karnataka and Goa is also nearby. We collect MSW, mainly the plastic waste and RDF in collaboration with the municipalities of the nearby areas. Goa is a hub of industries. We take all types of pharmaceutical wastes, bio medical waste from Karnataka, Goa and overall, a vicinity of 200 kilometers from our plant. Our contribution is about 77 to 80 per cent of plastic waste, consisting of mainly RDF and MSW. And rest of the waste is industrial waste which we get from various industries.

Except for limestone, which other raw materials can be used for clinker production?
As I mentioned earlier that we have to move towards maximising the use of alternative raw materials, lime mud that comes from the paper industry becomes and alternative raw material for us. It works well in place of limestone because of its higher lime content. Sometimes we even get about 45 to 55 per cent lime also. And at the same time, we have to promote low grade limestone with which we create a lighter clinker.
This low energy clinker hires 35 per cent lesser heat consumption than the conventional clinker production. It also contributes to huge reduction of carbon dioxide emission in terms of calcination and fuel reduction. This energy limestone in which MGO content is 13 to 15 per cent is being used as mineralizer. This material cannot be used in conventional cement manufacturing process. This high MGO limestone reduces the fuel consumption also.

What steps is your organisation taking to reduce the carbon footprint created by it?
The Confederation of Indian Industry (CII) is taking a good initiative for green gold ratings. Our Muddapur, Karnataka plant has received the Green Gold rating from CII in 2020. In this rating all sustainability goals are being included under various articles.
The major activities done to reduce the carbon footprint are energy efficiency, water conservation, renewable energy use, green house gases emission reduction, waste management, material conservation, recycling of materials, green supply chain, green ecology and infrastructure too.
For promoting of these activities, we are focusing our efforts on how to increase the production of blended cement up to 60 to 65 per cent of our total cement production. We are increasing additives up to the maximum permitted limits in blended cement like PPC. We are working on how to maximise the flag edition.
We have developed a new type of premium blended cement in place of Ordinary Portland cement (OPC) because we want to maximally promote the blended cements. This premium brand shall replace the OPC cement as it will be increasing the use of alternative fuels up to 30 per cent as compared to the current operation in the kiln which is 20 per cent alternative fuels. With this we have a clear roadmap of achieving 30 per cent GSR in the near future. Alongside a waste recovery system is also under progress.
We are targeting our energy roadmap to reach 55 unit per tonne of cement, an activity under progress, which is the national benchmark. We are adopting a shortest route for internal as well as external transport to minimise the greenhouse gas emissions.
Our organisation is focusing on all these activities to reduce the carbon footprint from the environment.

Tell us more about the role of technology and automation in the reduction of
carbon emission.

As I have mentioned that we are achieving a 20 per cent GSR. Furthermore, the cement plant is not able to cope up because the chloride per centage is more. What we shall now do is to utilise a chlorine bypass system that will help to further increase the GSR and take it up to 50 per cent GSR.
Once this is established, we are also proposing the installation of standard combustion system also to increase the utilization of alternative fuels, wastage recovery system, solar power plants and windmills as alternative sources of electronic energy. Also proposed is a system where we can produce low energy clinker and work with clay calcination
which can serve as an alternative to conventional clinker. We are now working on LC3 cement, which is a global standard technological innovation in the cement industry.

What happens to the waste generated by the cement manufacturing process in your organisation?
Generally, in cement industry there is no waste. However, some cement manufacturing processes have zero discharge, therefore there is no wastage. Agro waste and inhouse wastes are also processed in our pyroprocessing systems.
Our plants also use fly ash in the cement manufacturing process to make PPC as well as premium grade PPC cement also. There are some wastes produced such as electronic waste or medical waste which are further given to authorised recyclers to scrap properly.

Tell us more about the steps taken towards contributing towards the circular economy by your organisation?
The concept of circular economy has been applied in the cement industry for decades. Utilising byproducts of other industries and other secondary materials, we are a playing major role of ulitising more than 40 types of waste from various industries and we are using them as alternative fuels and raw materials in the cement manufacturing process.
A cement plant can be considered synonymous to Lord Shiva. It has the capability to inhale and hold waste of all types and can be use that with certain changes in our raw mix and cool mix. We have started using alternative fuels and raw materials in our cement plants since 2016. Now we are co-processing more than 1.25 lakh tonnes per year of alternative fuels. Last year we co-processed over 75 thousand tonnes and this year we have achieved 1.3 to 1.4 lakh tonnes of alternative fuels. Co-processing reduces the consumption of carbon intensive fuels as well as contributes towards the circular economy that can be used waste materials which would otherwise end up in landfills.
Supplementary cement materials such as fly ash from coal fired powered station, blast furnace slag and waste from the steel industry we are using as raw materials in the clinker manufacturing process.

What are the technological innovations or alternatives the organisation could opt for in future to ensure environment sustainability?
Our organisation is already in the process of working on the chlorine bypass system and combustion system. Other than this we have also aligned our business model with the UN 2030 agenda for sustainable development. We have committed a Science Based Target Initiative (SBTI) for business ambition to a well below 2 degree Celsius. Our company has also joined UN CC 2050 race to zero campaign under BCCA to achieve net zero emission for cement
and concrete.
Our target is to reduce specific thermal energy which is 704 by 2030. Specific power consumption that is around 65 by 2030. We have to increase our WHR capacity for efficiency improvement to 45 kilowatts per hour per tonne of clinker. To have to also increase green power mix use up to 75 per cent by 2030.
We are working on a road to green transportation. This is a transition to a greater use of electrical energy and renewable resources. Our target is to achieve a clinker ratio of 65 per cent by 2030. We are also working on increasing blended cement and how to minimise the use of exhaustible resources and move towards alternative resources.

By when is your organisation expected to achieve Net Zero and how much carbon emission has been reduced by 2021?
Our company has aligned itself to the UN mission of achieving Net Zero. We have been continuously working towards achieving that goal and our target is to achieve 80 per cent of that by 2030. As mentioned earlier, we have targeted to achieve thermal energy consumption of 704 for the whole organisation and not an individual plant.
For individual plants, like this, Muddapur plant, we are running on with a 685 specific heat and the total power is 62 to 65. In the totality of the whole organisation, we have taken up the target of 2030 and will achieve the same. Net zero achievement shall be around 2050.
What I would also like to add on here is that the cement industry in the future is only going to survive on alternative fuels and raw materials. We have to source, utilise and promote the use of alternatives as in India, the average thermal rate is only 4 to 5 per cent. We have to identify the plants where it is only 2 to 3 per cent and start from there and take it up to 20 to 30 per cent. The Indian average should be 20 per cent to achieve a sustainable environment. Plants that are using alternative fuels and alternative raw materials have to work hard to achieve this thermal substitution rate.
These are natural resources, and the reserves will deplete after some years. We have to consciously think about the next generation and make an effort. Cement industry has to take a lead to towards a sustainable journey. They must move forward and take certifications on a global scale for greener methods and processes too.

Kanika Mathur

Concrete

Adani’s Strategic Emergence in India’s Cement Landscape

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Milind Khangan, Marketing Head, Vertex Market Research, sheds light on Adani’s rapid cement consolidation under its ‘One Business, One Company’ strategy while positioning it to rival UltraTech, and thus, shaping a potential duopoly in India’s booming cement market.

India is the second-largest cement-producing country in the world, following China. This expansion is being driven by tremendous public investment in the housing and infrastructure sectors. The industry is accelerating, with a boost from schemes such as PM Gati Shakti, Bharatmala, and the Vande Bharat corridors. An upsurge in affordable housing under the Pradhan Mantri Awas Yojana (PMAY) further supports this expansion. In May 2025, local cement production increased about 9 per cent from last year to about 40 million metric tonnes for the month. The combined cement capacity in India was recorded at 670 million metric tonnes in the 2025 fiscal year, according to the Cement Manufacturers’ Association (CMA). For the financial year 2026, this is set to grow by another 9 per cent.
In spite of the growing demand, the Indian cement industry is highly competitive. UltraTech Cement (Aditya Birla Group) is still the market leader with domestic installed capacity of more than 186 MTPA as on 2025. It is targeted to achieve 200 MTPA. Adani Cement recently became a major player and is now India’s second-largest cement company. It did this through aggressive consolidation, operational synergies, and scale efficiencies. Indian players in the cement industry are increasingly valuing operational efficiency and sustainability. Some of the strategies with high impact are alternative fuels and materials (AFR) adoption, green cement expansion, and digital technology investments to offset changing regulatory pressure and increasing energy prices.

Building Adani Cement brand
Vertex Market Research explains that the Adani Group is executing a comprehensive reorganisation and consolidation of its cement business under the ‘One Business, One Company’ strategy. The plan is to integrate its diversified holdings into one consolidated corporate entity named Adani Cement. The focus is on operating integration, governance streamlining, and cost reduction in its expanding cement business.
Integration roadmap and key milestones:

  • September 2022: The consolidation process started with the $6.4 billion buyout of Holcim’s majority stakes in Ambuja Cements and ACC, with Ambuja becoming the focal point of the consolidation.
  • December 2023: Bought Sanghi Industries to strengthen the firm’s presence in western India.
  • August 2024: Added Penna Cement to the portfolio, improving penetration of the southern market of India.
  • April 2025: Further holding addition in Orient Cement to 46.66 per cent by purchasing the same from CK Birla Group, becoming the promoter with control.
  • Ambuja Cements amalgamated with Adani Cement: This was sanctioned by the NCLT on 18th July 2025 with effect from April 1, 2024. This amalgamation brings in limestone reserves and fresh assets into Ambuja.
  • Subject to Sanghi and Penna merger with Ambuja: Board approvals in December 2024 with the aim to finish between September to December 2025.
  • Ambuja-ACC future integration: The latter is being contemplated as the final step towards consolidation.
  • Orient Cement: It would serve as a principal manufacturing facility following the merger.

Scale, capacity expansion and market position
In financial year-2025, Adani Cement, including Ambuja, surpassed 100 MTPA. This makes it one of the world’s top ten cement companies. Along with ACC’s operations, it is now firmly placed as India’s second-largest cement company. In FY25, the Adani group’s sales volume per annum clocked 65 million metric tonnes. Adani Group claims that it now supplies close to 30 per cent of the cement consumed in India’s homes and infrastructure as of June 2025.
The organisation is pursuing aggressive brownfield expansion:

  • By FY 2026: Reach 118 MTPA
  • By FY 2028: Target 140 MTPA

These goals will be driven by commissioning new clinker and grinding units at key sites, with civil and mechanical works underway.
As of 2024, Adani Cement had its market share pegged at around 14 to 15 per cent, with an ambition to scale this up to 20 per cent by FY?2028, emerging as a potent competitor to UltraTech’s 192?MTPA capacity (186 domestic and overseas).

Strategic advantages and competitive benefits
The consolidation simplifies decision-making by reducing legal entities, centralising oversight, and removing redundant functions. This drives compliance efficiency and transparent reporting. Using procurement power for raw materials and energy lowers costs per ton. Integrated logistics with Adani Ports and freight infrastructure has resulted in an estimated 6 per cent savings in logistics. The group aims for additional savings of INR 500 to 550 per tonne by FY 2028 by integrating green energy, using alternative fuel resources, and improving sourcing methods.

Market coverage and brand consistency
Brand integration under one strategy will provide uniform product quality and easier distribution networks. Integration with Orient Cement’s dealer base, 60 per cent of which already distributes Ambuja/ACC products, enhances outreach and responsiveness.
By having captive limestone reserves at Lakhpat (approximately 275 million tonnes) and proposed new manufacturing facilities in Raigad, Maharashtra, Adani Cement derives cost advantage, raw material security, and long-term operational robustness.

Strategic implications and risks
Consolidation at Adani Cement makes it not just a capacity leader but also an operationally agile competitor with the ability to reap digital and sustainability benefits. Its vertically integrated platform enables cost leadership, market responsiveness, and scalability.

Challenges potentially include:

  • Integration challenges across systems, corporate cultures, and plant operations
  • Regulatory sanctions for pending mergers and new capacity additions
  • Environmental clearances in environmentally sensitive areas and debt management with input price volatility

When materialised, this revolution would create a formidable Adani–UltraTech duopoly, redefining Indian cement on the basis of scale, innovation, and sustainability. India’s leading four cement players such as Adani (ACC and Ambuja), Dalmia Cement, Shree Cement, and UltraTech are expected to dominate the cement market.

Conclusion
Adani’s aggressive consolidation under the ‘One Business, One Company’ strategy signals a decisive shift in the Indian cement industry, positioning the group as a formidable challenger to UltraTech and setting the stage for a potential duopoly that could dominate the sector for years to come. By unifying operations, leveraging economies of scale, and securing vertical integration—from raw material reserves to distribution networks—Adani Cement is building both capacity and resilience, with clear advantages in cost efficiency, market reach, and sustainability. While integration complexities, regulatory hurdles, and environmental approvals remain key challenges, the scale and strategic alignment of this consolidation promise to redefine competition, pricing dynamics, and operational benchmarks in one of the world’s fastest-growing cement markets.

About the author:
Milind Khangan is the Marketing Head at Vertex Market Research and comes with over five years of experience in market research, lead generation and team management.

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Precision in Motion: A Deep Dive into PowerBuild’s Core Gear Series

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PowerBuild’s flagship Series M, C, F, and K geared motors deliver robust, efficient, and versatile power transmission solutions for industries worldwide.

Products – M, C, F, K: At the heart of every high-performance industrial system lies the need for robust, reliable, and efficient power transmission. PowerBuild answers this need with its flagship geared motor series: M, C, F, and K. Each series is meticulously engineered to serve specific operational demands while maintaining the universal promise of durability, efficiency, and performance.
Series M – Helical Inline Geared Motors: Compact and powerful, the Series M delivers exceptional drive solutions for a broad range of applications. With power handling up to 160kW and torque capacity reaching 20,000 Nm, it is the trusted solution for industries requiring quiet operation, high efficiency, and space-saving design. Series M is available with multiple mounting and motor options, making it a versatile choice for manufacturers and OEMs globally.
Series C – Right Angled Heli-Worm Geared Motors: Combining the benefits of helical and worm gearing, the Series C is designed for right-angled power transmission. With gear ratios of up to 16,000:1 and torque capacities of up to 10,000 Nm, this series is optimal for applications demanding precision in compact spaces. Industries looking for a smooth, low-noise operation with maximum torque efficiency rely on Series C for dependable performance.
Series F – Parallel Shaft Mounted Geared Motors: Built for endurance in the most demanding environments, Series F is widely adopted in steel plants, hoists, cranes, and heavy-duty conveyors. Offering torque up to 10,000 Nm and high gear ratios up to 20,000:1, this product features an integral torque arm and diverse output configurations to meet industry-specific challenges head-on.
Series K – Right Angle Helical Bevel Geared Motors: For industries seeking high efficiency and torque-heavy performance, Series K is the answer. This right-angled geared motor series delivers torque up to 50,000 Nm, making it a preferred choice in core infrastructure sectors such as cement, power, mining, and material handling. Its flexibility in mounting and broad motor options offer engineers’ freedom in design and reliability in execution.
Together, these four series reflect PowerBuild’s commitment to excellence in mechanical power transmission. From compact inline designs to robust right-angle drives, each geared motor is a result of decades of engineering innovation, customer-focused design, and field-tested reliability. Whether the requirement is speed control, torque multiplication, or space efficiency, Radicon’s Series M, C, F, and K stand as trusted powerhouses for global industries.

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Driving Measurable Gains

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Klüber Lubrication India’s Klübersynth GEM 4-320 N upgrades synthetic gear oil for energy efficiency.

Klüber Lubrication India has introduced a strategic upgrade for the tyre manufacturing industry by retrofitting its high-performance synthetic gear oil, Klübersynth GEM 4-320 N, into Barrel Cold Feed Extruder gearboxes. This smart substitution, requiring no hardware changes, delivered energy savings of 4-6 per cent, as validated by an internationally recognised energy audit firm under IPMVP – Option B protocols, aligned with
ISO 50015 standards.

Beyond energy efficiency, the retrofit significantly improved operational parameters:

  • Lower thermal stress on equipment
  • Extended lubricant drain intervals
  • Reduction in CO2 emissions and operational costs

These benefits position Klübersynth GEM 4-320 N as a powerful enabler of sustainability goals in line with India’s Business Responsibility and Sustainability Reporting (BRSR) guidelines and global Net Zero commitments.

Verified sustainability, zero compromise
This retrofit case illustrates that meaningful environmental impact doesn’t always require capital-intensive overhauls. Klübersynth GEM 4-320 N demonstrated high performance in demanding operating environments, offering:

  • Enhanced component protection
  • Extended oil life under high loads
  • Stable performance across fluctuating temperatures

By enabling quick wins in efficiency and sustainability without disrupting operations, Klüber reinforces its role as a trusted partner in India’s evolving industrial landscape.

Klüber wins EcoVadis Gold again
Further affirming its global leadership in responsible business practices, Klüber Lubrication has been awarded the EcoVadis Gold certification for the fourth consecutive year in 2025. This recognition places it in the top three per cent
of over 150,000 companies worldwide evaluated for environmental, ethical and sustainable procurement practices.
Klüber’s ongoing investments in R&D and product innovation reflect its commitment to providing data-backed, application-specific lubrication solutions that exceed industry expectations and support long-term sustainability goals.

A trusted industrial ally
Backed by 90+ years of tribology expertise and a global support network, Klüber Lubrication is helping customers transition toward a greener tomorrow. With Klübersynth GEM 4-320 N, tyre manufacturers can take measurable, low-risk steps to boost energy efficiency and regulatory alignment—proving that even the smallest change can spark a significant transformation.

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